Apparatus for securing a solar panel rail guide to a support bracket

ABSTRACT

In various representative aspects, an assembly for securing a support bracket to rail guide used for mounting and installing solar panels is provided. More specifically, the assembly provides a novel and improved nut with a serrated surface in combination with a t-bolt with a serrated surface that is capable of penetrating the respective oxidation surface layers of the bracket and the rail guide when installed. When installed, provides a mechanism for using the bracket to connect the rail guide to a flashing that is typically installed on a roof. By employing the apparatus at various locations along the roof in a linear fashion, the rail support structure can be properly installed so that an array of solar panel modules to be installed.

BACKGROUND OF INVENTION

Field of the Invention

The present invention relates generally to an apparatus for securing a bracket to a solar panel rail support structure, while providing an electrical bonding path between the bracket and the support structure. More specifically, the apparatus provides a novel and improved nut with a serrated surface in combination with a bolt with an enlarged end like t-bolt with a serrated surface that is capable of penetrating the respective oxidation surface layers of the bracket and the rail guide. The combination is typically used to secure a bracket, and as described herein by way of example, an L-shaped bracket. By employing the apparatus at various locations along the roof in a linear fashion, the rail support structure can be properly installed so that an array of solar panel modules to be installed.

Description of the Related Art

Any discussion of the prior art in the specification should in no way be considered as an admission that the prior art is widely known or forms part of common general knowledge in the field.

The installation of solar panel arrays on residential roofs can be arduous and time-consuming. Depending on the array design, the components required to install the array can make the installation process even more difficult. Many of the assembly components require special tools or are generally difficult to install because they are utilized after the solar panels modules are arranged or positioned on their support elements. This is particularly true when the elements must be installed on a roof that links to a rail guide for supporting the solar panel array.

In a typical support rail guide system, solar panel modules are arranged across the top of several rail guides. This typically occurs, for example, by using mounting clamps that join two solar panel modules along the top of the rail guide. The rail guides in turn are supported by flashings that are connected by using a support bracket between the flashing and the rail guide. A typical support bracket is in the shape of an “L”, but can be any suitable shape that serves to connect the flashing to the rail guide.

When connecting the support bracket between the flashing and the rail guide, a nut and bolt combination is typically used. The present invention employs a combination bolt with an enlarged end and nut that not only secures the bracket to the rail guide, but also provides an electrical bonding path between the rail guide and the bracket.

Existing solutions are typically limited by their inability to easily and precisely secure the bracket to the rail guide while using extra bonding washers or bonding components, while also creating an electrical bonding path. One example of this is shown in U.S. Pat. No. 7,073,995 issued to Herb. The '995 patent discloses a nut and bolt combination that has an elongated member 4 that can fit in a mounting rail 3. The elongated member has a recessed portion 18.1 and 18.2 that is adapted to receive holding projections 17.1 and 17.2 respectively when screw 8 is tightened into the elongated member. The screw can also have indentations 38 (FIG. 4b), but these indentations are provided solely to engage servo components 33 to form a locking mechanism. The '995 patent does not teach or suggest a combination nut and bolt wherein the bolt has an elongated member such that the elongated member and the bottom surface of the nut include raised portions for penetrating the surface layer of metal objects to create an electrical bonding path between them. The '995 patent also does not disclose that the elongated member of the bolt can be inserted lengthwise in a slot of a solar panel rail guide, engage the rail guide so that raised portions on the elongated member penetrate a surface treatment layer of the rail guide when the nut is tightened, and have the raised portions of the nut engage a bracket that supports the rail guide and penetrate the surface treatment layer of the bracket as well, which creates an electrical bonding path between these objects. The present invention overcomes the limitations of the '995 patent.

The present invention overcomes these limitations and offers a solution that provides a nut and bolt combination that secures a support bracket to a solar panel rail guide slot that creates an electrical bonding path between the rail guide and the bracket that is easy to install, use, and manufacture.

SUMMARY OF THE INVENTION

The invention is summarized below only for purposes of introducing embodiments of the invention. The ultimate scope of the invention is to be limited only to the claims that follow the specification.

It is an object of this invention to provide an assembly for securing a bracket to a solar panel rail guide structure.

It is a further object of this invention that the assembly comprise a bolt that comprises an elongated member on an end of the bolt.

It is a further object of this invention that the elongated member comprises a raised portion capable of penetrating a surface layer of a solar panel rail guide.

It is a further object of this invention that a nut engages an end opposite the elongated member on the bolt.

It is a further object of this invention that the nut comprises a raised portion capable of penetrating a surface layer of a bracket that supports the solar panel rail guide.

It is a further object of this invention that the elongated member be capable of insertion lengthwise along the length of the solar panel rail guide slot such that when the elongated member is rotated when turned by the nut, the elongated member will engage the slot of the rail guide and enable the nut to turn until the support bracket is secured between the nut and the solar panel rail guide.

A person with ordinary skill in the relevant art would know that any shape or size of the elements described below may be adopted. Any combinations of suitable number, shape, and size of the elements described below may be used. Also, any materials suitable to achieve the object of the current invention may be chosen as well.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention may be derived by referring to the detailed description and claims when considered in connection with the following illustrative figures. In the following figures, like reference numbers refer to similar elements and steps throughout the figures.

FIG. 1 illustrates a perspective view of an exemplary nut.

FIG. 2 illustrates a side view of the nut shown in FIG. 1.

FIG. 3 illustrates a perspective view of the nut shown in FIG. 1 coupled to a bolt with an elongated member.

FIG. 4 illustrates a reverse perspective view of FIG. 3.

FIG. 5 illustrates a perspective view of a fully assembled exemplary bracket to an exemplary rail guide using the nut and bolt combination shown in FIGS. 3 and 4.

FIG. 6 illustrates a cross-sectional view of FIG. 5 showing the nut and bolt securing the bracket to the solar panel rail guide.

FIG. 7 illustrates a close up view of the circled area 7 in FIG. 6 showing the raised portions on the nut and bolt penetrating the surfaces of the bracket and solar panel rail guide respectively.

DETAILED DESCRIPTION OF THE INVENTION

In the following description, and for the purposes of explanation, numerous specific details are provided to thoroughly understand the various aspects of the invention. It will be understood, however, by those skilled in the relevant arts, that the present invention may be practiced without these specific details. In other instances, known structures and devices are shown or discussed more generally in order to avoid obscuring the invention. In many cases, a description of the operation is sufficient to enable one to implement the various forms of the invention, particularly when the operation is to be implemented in software. It should be noted that there are many different and alternative configurations, devices and technologies to which the disclosed embodiments may be applied. The full scope of the invention is not limited to the example(s) that are described below.

FIGS. 1 and 2 show perspective and side views respectively of an exemplary embodiment of a nut 100. The nut 100 is typically made of metal or an electrically conducting material. The nut 100 includes head 110. The head 110 shown in this embodiment includes two parts—a large hexagonal portion 110, and a smaller hexagonal portion 115 that is to the rear of the larger portion 110. These hexagonal portions 110 and 115 provide a gripping structure for human hands as well as two sizes of socket wrenches or pliers to enable the nut 100 to be turned for tightening or loosening. It is understood by those skilled in the art that the shape of the gripping structure can be hexagonal, or of any suitable shape that provides a secure connection. The nut 100 also includes a female threaded portion 130 for receiving the bolt 150 as shown in FIG. 3. An annular flange 120 is provided on the lower end of the nut 100. The flange 120 is not limited to the annular shape and can also be of any suitable shape. It is also understood that the flange 120 can be the same or greater diameter of the large hexagonal portion 110. The annular flange 120 also includes serrated portions 140 on the bottom surface of the flange 120. The serrated portions 140 can number as few as one, or as many as can be reasonably fit along the surface of the flange 120. The serrated portions 140 should also be as sharp as necessary for them to be able to penetrate a surface layer of a support bracket 300 as shown in FIG. 5 to form a conducting bond between the support bracket 300 and the flange 120.

FIGS. 3 and 4 illustrate perspective views of an exemplary combination nut 100 and bolt 155. The bolt 155 is typically what is described as a “t-bolt” and includes a threaded shank 150 that extends outward from one side of an enlarged end 160. The shank 150 and the enlarged end 160 are coupled either in two elements or as a single part. The enlarged end 160 is typically in the shape of a rectangular prism and, along with the shank 150, is electrically conductive. Generally, the size of the enlarged end 160 should allow it to be inserted lengthwise into a slot 230 on the rail guide 200 as will be discussed below in FIGS. 5-7, yet capable of being rotated into a locked position as shown in FIGS. 6-7 so that the enlarged end 160 is substantially perpendicular to the opening of the slot 230. As shown in FIGS. 3-4, the shank 150 is engaged with the nut 100 by screwing it into the female threaded portion 130. On the top surface of the enlarged end 160 where the shank 150 extends outward, a plurality of raised portions 170 are included. These raised portions 170 are generally sharp enough so that they can penetrate the surface layer of an electrically conducting material and create an electrical conducting path between the raised portions 170 and that material. The raised portions 170 can number as few as one. But generally, a greater number of raised portions 170 that are present on the surface create a better electrical conducting path.

FIG. 5 illustrates an exemplary installation of the assembly. As shown, the rail guide 200 is coupled to the support bracket 300 by way of the nut 100 and bolt 155 combination. The top rail 220 on the rail guide 200 is generally used to support several solar panel modules. A clamp (not shown) fits within the slot of 220 and connects and electrically bonds the modules. Generally, the rail guide 200 extends for a long distance from one end of a roof to another and is supported by multiple support brackets 300 separated by distinct distances apart.

Although the enlarged end 160 can be inserted at the slot end 210, this is not desirable when the rail guide 200 extends for several feet across a roof. For this reason, inserting each enlarged end 160 lengthwise at discrete distances along the slot 230 overcomes this limitation. Once inserted, the nut 110 is then engaged with the threaded shank portion 150 and is typically rotated by hand without the use of extra tools to secure it to the shank 150. As the nut 110 is rotated, the enlarged end 160 rotates inside of the slot 230 and stops rotating when the edges of the enlarged end 160 are perpendicular to, and in contact with the inside surface of the slot 230.

Once the enlarged end 160 is engaged with the inside surface of the slot 230, the support bracket 300 is then inserted between the nut and the face 240 of the rail guide 200 along the aperture 330 and moved into position until a desired height is achieved. The nut 110 is then rotated until the serrations 140 begin to contact the surface of the bracket 300. As the nut 110 is further rotated and tightened, the serrations 140 will penetrate the surface layer of the bracket 300 and the raised portions 170 on the enlarged end 160 begin to penetrate the surface layer of the slot 230 within the rail guide 200 as shown in more detail in FIGS. 6-7. This in turn creates an electrical bonding path between the rail guide 200 and the bracket 300. Gripping features 320 can also provide greater stability for the bracket 300 to further prevent it from sliding up or down when the face of the rail guide 200 once the bracket 300 is secured. When the bracket 300 is electrically coupled to a flashing (not shown) through opening 310, and the rail guide 200 is electrically coupled to solar panel modules along its top rail 220, the solar panel array is fully electrically connected. 

What is claimed is:
 1. An assembly for facilitating the completion of an electrical circuit between a first and second object comprising: a. a solar panel rail guide comprising: i. a slot comprising: an opening along its length and; a surface treatment layer; b. a support bracket comprising: i. an aperture and; ii. a surface treatment layer; c. a bolt comprising; i. an enlarged end comprising at least one raised portion on a top surface of the enlarged end for penetrating the surface treatment layer of the slot of the solar panel rail guide; ii. a shank having a first end and a second end wherein the first end is coupled to the top surface of the enlarged end so that the shank is perpendicular to the enlarged end; d. a nut comprising at least one serration on a bottom side of the nut for penetrating the surface treatment layer of the support bracket and the nut being coupled to the second end of the shank through an opening on the bottom side; e. the enlarged end being insertable in a first orientation through the opening along the length of the solar panel rail guide and rotatable to a second orientation such that the enlarged end engages the solar panel rail guide.
 2. The assembly of claim 1 wherein the shank is threaded.
 3. The assembly of claim 2 where in the opening on the bottom side of the nut is threaded and adapted to engage the threaded shank by rotating the nut around the threaded shank.
 4. The assembly of claim 1 wherein the nut further comprises a gripping structure on a top side of the nut.
 5. A method of installing a solar panel rail guide to a support structure comprising the steps of: a. Inserting an enlarged end of a bolt into an opening of a slot along a length of a solar panel rail guide wherein the bolt further comprises a shank extending from the enlarged end; b. coupling a nut to an end opposite the enlarged end of the bolt; c. inserting a support bracket between the nut and the slot of the solar panel rail guide so that the shank fits through an opening of the support bracket; d. rotating the nut so that the enlarged end rotates to a position substantially perpendicular to the opening of the slot and engages the slot; e. continuing to rotate the nut until at least one serration on a bottom surface of the nut penetrates a surface oxidation layer of the support bracket and at least one raised portion on a top surface of the enlarged end penetrates a surface oxidation layer of the slot and creates an electrical grounding path between the solar panel rail guide and the support bracket. 